Off-Board Pulsating Buffer Converter for EV On-Board Chargers
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Solution Overview
Problem
Conventional on-board chargers for electric vehicles face challenges with bulky and costly energy storage elements, leading to reduced power density and increased costs due to the use of electrolytic capacitors, which affect the maximum operating temperature and reliability.
Innovation Solution
The implementation of a pulsating buffer converter system that includes a housing, printed circuit board, inductor, and capacitor, where the inductor and capacitor are positioned off-board to interface with power switches, reducing the size of energy storage components and enhancing power density by eliminating current ripple and transforming AC/DC converter output into a battery-level DC output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrolytic capacitors are used for energy storage in conventional on-board chargers, then the charging function is achieved, but the power density is reduced and costs increase due to bulky components
Solution Approach 1:
The patent extracts the inductor from the PCB and positions it off-board, separating it from the control circuitry. This extraction allows for optimized component placement and reduces the overall footprint of the charger system, directly addressing the volume reduction goal while maintaining reliability
Solution Approach 2:
The patent transitions from a conventional PCB-integrated layout to a three-dimensional spatial arrangement where inductors are positioned off-board. This dimensional change enables better heat dissipation, reduced electromagnetic interference, and optimized component spacing, thereby improving reliability without increasing volume
2Productivity
If conventional on-board charger design is used, then charging functionality is provided, but power density is reduced due to bulky energy storage elements
Solution Approach 1:
The patent segments the on-board charger into distinct functional modules: PCB-based control circuitry and off-board energy storage components (inductors and capacitors). This segmentation allows each component to be optimized independently for its specific function, reducing overall volume while maintaining high power density
Solution Approach 2:
The patent implements dynamic switching control of the power switches positioned on the PCB, which efficiently manages energy transfer between the off-board inductors/capacitors and the battery. This dynamic control optimizes the charging process, enabling high power density without requiring proportionally larger energy storage components
3Quantity of substance
If electrolytic capacitors are used in conventional designs, then energy storage is achieved, but costs increase due to bulky and expensive components
Solution Approach 1:
The off-board inductors and capacitors serve multiple functions: energy storage, current ripple filtering, and thermal management. This multi-functionality reduces the need for additional specialized components, lowering overall bill of materials cost while maintaining required energy storage capacity
Solution Approach 2:
The patent employs standard, readily available inductor and capacitor components that can be manufactured at lower costs compared to specialized electrolytic capacitors. These components are positioned off-board where they can be easily replaced if needed, reducing lifecycle costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces the size of energy storage capacitors, improves power density, and extends the operating temperature and reliability of on-board chargers, while also enabling cost-effective and efficient charging of electric vehicle traction batteries.
Implementation Method 1
at least one inductor positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least second power switch
Implementation Method 2
at least one capacitor positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least one second power switch to regulate an energy output
Data Source
AI summary
In at least one embodiment, an apparatus including a pulse buffer (PB) converter. The PB converter including a housing, a printed circuit board (PCB), at least one inductor, and at least one capacitor is provided. The PCB is positioned in the housing and includes at least one first power switch and at least one second power switch positioned thereon. The at least one inductor is positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least second power switch. The at least one capacitor is positioned in the housing and off board from the PCB to interface with the at least one first power switch and the at least one second power switch to regulate an energy output to one or more vehicle batteries during a charging operation.